JP3130956B2 - Materials for surface treatment - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

FIELD OF THE INVENTION The present invention relates to a three-dimensional web and a non-woven surface finishing material having a reinforced support formed of a polymer layer. The invention also relates to a method of making the material, comprising the step of coating the web with a layer of a polymeric material.

[0002]

2. Description of the Related Art Non-woven three-dimensional fiber grinding products (non woven t
hree-dimentional fibrous abrasive products) have been used on a variety of materials, such as aluminum, brass, copper, iron, wood, etc., to remove corrosion, surface defects, burrs, and provide a desirable surface finish. US Patent 2,958,593
Nonwoven, lofty, three-dimensional, fibrous grinding products made according to the methods described in the above-cited patents have often been used extensively. These grinding products are used in the form of discs and belts. However, the endless belt form has the disadvantage that it easily sags at sharp edges. Also, this belt has insufficient breaking strength in many applications.

Methods for reinforcing such non-woven, bulky, three-dimensional grinding products have been reported in various documents. U.S. Pat. No. 3,324,609 describes an attempt to reinforce a nonwoven fibrous web by needle tacking a three-dimensional web to a supporting web. U.S. Pat.No. 3,688,453 discloses another method of reinforcing a three-dimensional fibrous web by needle tacking web-forming fibers to a reinforcing scrim and impregnating the resulting structure with a bonding material containing abrasive particles. A method is described. Although this scrim-reinforced nonwoven grinding product can be used extensively, it does not have the stretch resistance required when used in belt form. U.S. Pat. No. 4,331,453 discloses a peel resistant grinding belt and disc having a bulky, nonwoven, three dimensional grinding web adhesively laminated to a stretch resistant reinforced woven fabric with an adhesive polyurethane bonding material. US Patent 4,609,581
No. 2 covers the fiber surface of the support with a hot melt adhesive to fix the fibers in the support and prepare a smooth surface for subsequent application of liquid adhesive and abrasive particles. A seat structure is disclosed. Although such products are stretch resistant, they are slack resistant (snag
There is a need for flexible products that have resistant.

[0004] Improvements in bulky, fibrous grinding belts that have been made to date are described in US Patent Nos. 4,331,453 and 3,688,453. Preferably, these solid, bulky, fibrous grinding materials are stretch resistant,
Low friction, durability, and sag resistance. In U.S. Pat. No. 3,688,453, an improved product is made by using a porous mesh fabric instead of a woven fabric.
These improved stretch resistant nonwoven grinding belts are sag resistant and are used successfully supported by wheels that contact the opposite side of the material being finished. However,
In applications where such a belt is supported by an installed platen, excessive friction between the platen and the fibers protruding through the woven fabric results in excessive wear and heating of the platen. This results in rattling of the operation of the belt, non-uniform surface finish in the material, and excessive platen wear. Therefore, a need has arisen for a grinding material whose fibers do not protrude from the back surface.

[0005] Despite the above-mentioned patents, there is a need for durability, sag resistance, stretch resistance, low friction, backless fiber, fibrous ground or polished products.

[0006]

SUMMARY OF THE INVENTION The present invention provides bulky, low density, fibrous, nonwoven materials suitable for grinding and polishing belts, pads, disks, and the like. The material of the present invention has the following (a) and (b): (a) having a porous, bulky web that is bonded with a bonding material at points where the synthetic fibers are crimped and substantially contact each other And (b) a reinforcing polymer layer fused to one major surface of the nonwoven layer and into which the ends of the fibers derived from the nonwoven layer have been introduced. This polymer layer provides a smooth, flexible, low-friction surface with substantially no fiber protrusion by covering the fibrous backside of the bulky nonwoven grinding product. The polymer layer also provides strength to the three-dimensional nonwoven product.

[0007] The present invention also provides bulkiness, low density,
Provided is a method for producing a fibrous or non-woven material. The method comprises the following steps (a), (b) and (c): (a) a porous bulky synthetic fiber which is crimped and adhered with a bonding material at points of substantial mutual contact Providing a nonwoven three-dimensional sheet material having a non-woven web; (b) applying a coating composition that cures to form a solid polymer layer on one major surface of the nonwoven layer; and c) curing the composition.

[0008]

DETAILED DESCRIPTION OF THE INVENTION There are several different forms of the grinding or polishing material of the present invention. Although both the belt and the disc are shown in the figures, other configurations are also contemplated. Generally, the present invention deals with a ground or polished layer that is securely fixed to a reinforced polymer support in the form of a belt or disk. The term "reinforcement" broadly refers to a flexible support structure. Previous grinding and polishing belts tended to stretch after use, which prevented the belt from being properly mounted on the belt drive of the surfacing device. Other disadvantages include lack of flexibility, sagging of the woven support, insufficient support strength, and excessive friction at the platen surface. The use of a polymer support solves these problems and offers other advantages in the grinding and polishing fields.

FIG. 1 shows a grinding belt 10 according to the present invention. The three-dimensional fibrous layer 11 and the optional stretch-resistant reinforced woven fabric 12 are shown as a composite structure. Here, some of the fibers of the three-dimensional fibrous layer 11 pass through the stretch-resistant reinforcing woven fabric 12 and extend to form the second fibrous layer 13 on the opposite side of the stretch-resistant reinforcing woven fabric 12. The polymer layer 14 is formed so as to surround the fibrous layer 13. FIG. 3 shows grinding or polishing as a composite of a three-dimensional fibrous layer 11, an optional stretch resistant reinforced woven fabric 12, a second fibrous layer 13 protruding therethrough and a solidified polymer layer 14. 2 shows a part of the material 10 for use. FIG. 4 shows a three-dimensional fiber layer 1 for three-dimensional fiber grinding or polishing.
1 and another grinding material 15 covering a fiber adjacent to one surface of the three-dimensional fibrous layer 11 and having a partially penetrated solidified polymer layer 14 is shown.

FIG. 6 shows a part of a conventional material having a three-dimensional fibrous layer 11 and a reinforcing cloth 16. Here, the fibers of the fibrous layer 11 form the second fibrous layer 13 protruding without being obscured on the opposite side of the woven fabric 12 because there is no polymer layer on the back surface of the reinforcing cloth 16. .

The material of the present invention may be in the form of an endless belt or disk 17 (shown in FIG. 2) having a central hole 18 for ease of wearing.

The bulky, porous, low density, fibrous, non-woven web portion of material 10 (three-dimensional fibrous layer 11) is made of nylon,
Any synthetic fiber that withstands the temperature of impregnating a resin such as polyester, etc., and cures without degradation of the grinding joint material can be used. Preferably, the fibers are drawn and crimped. Fibers that can be used as the nonwoven portion are about 20 to about 100 mm in length, preferably about 40 to about 65 mm, and have a denier of about 1.5 to about 500, preferably 15 to 100. Mixed denier fibers are optionally used to achieve the desired surface finish. In addition, larger abrasive particles can be used by using larger fibers. The nonwoven web is called `` Rando Weber
Webber) machine (Curlator Corporatio
n) or easily formed by other conventional curling processes. Fibrous portion of this material preferably contains at least about 100, more preferably the fibers in an amount of about 250 g / m ^2. When the amount of fiber is small, the service life of the belt is shortened. Typically, such a weight of fiber provides a web thickness of about 6 to about 75 mm, preferably about 25 mm, before needling or impregnation.

The nonwoven web 11 is fixed to the nonwoven fabric by needle tacking. Needle tacking is a method of attaching a nonwoven web to a woven fabric. Barbed ne
The edle is pressed through the nonwoven web and passed through the woven fabric, and the barbed needle is pulled along the fibers of the nonwoven web.
The needle is then pulled back, leaving the fibers of the web alone or bonded to the woven fabric collected. The amount or degree of needle tacking required to provide a useful grinding material is determined by a 15 x 18 x 25 x 3.5 RB6-32-5.5 / B / 3B / 2E needle (from Foster Needle Company). (Available) requires at least about 8, preferably about 20, needle passes per cm ^{2 of} web surface. This needle tacking was developed by James Hunter Machine Company
This is easily accomplished using conventional needle looms that are more commercially available.

After needle tacking, this material is
Using a two-roll coater, the fibers of the nonwoven and woven fabrics are completely immersed in the abrasive material with a resin-abrasive particle slurry or a resin binder if desired. By solidifying the resin, the nonwoven fibers are securely fixed to the woven fabric support. Preferred resins are those that are relatively hard and provide strong adhesion between the nonwoven fibers and between the nonwoven fibers and the woven substrate. Preferred resins include phenol-formaldehyde, epoxy, polyurethane, urea-formaldehyde, and other resins that are commercially available for producing nonwoven, low density grinding materials. The top surface is coated with the resin-abrasive particle slurry by spray coating or other coating methods. Suitably, the nonwoven surface should have a Shore A hardness of about 25 to 85 as measured using a 5 mm measuring part diameter instrument for the grinding mineral coated belt used to finish the material. Belts with a low durometer easily sag and are easily torn by sharp edges in the finishing material. Belts with a durometer above this range are overly dense, increase the load on the grinding shards, function like sandpaper, and provide the uniform finish expected of nonwoven abrasive materials. I can't.

Generally, the abrasive particles used as needed are fine powders of 24 grade or less usually used for polishing, and include aluminum oxide, silicon carbide, talc, cerium oxide, garnet, flint, emery and the like. You. If necessary, a metal working lubricant such as grease, oil, stearic acid ester or the like is incorporated into the three-dimensional layer of the belt or disk of the present invention and used.

This material can also be used as a workpiece.
s) Can be used for polishing. If this material is used for polishing, no resin-abrasive particle slurry is applied to the nonwoven surface.

If a woven support is used, it is an elongation resistant woven fabric that has a low elongation value when pulled in the opposite direction. Linear meter widt
h) with a force of 175 × 10 ² Newtons,
This elongation value is less than about 5%, preferably less than about 2.5%.
Preferred materials for providing the fabric support of the grinding product are the conventional fabric support materials used in coated grinding products. Such a woven fabric support is preferably a woven nylon fabric, a polyester or cotton fabric represented by twill, jeans or a woven fabric of a raw fiber material accompanied by a polyester greige cloth. Such woven fabrics are typically
Treated with sizing agent. Such a treatment is preferred for producing the grinding product of the present invention. Such a woven fabric must be selected to be compatible with the solvent, bonding material, and process environment used to prepare the grinding or polishing product of the present invention.

The polymer layer impregnated and covering the fibrous back of the nonwoven web spreads and flows on the fibrous back,
Proper curing forms a continuous layer that obscures one outer surface of the web without significant penetration across the reinforcement, wall thickness, and balance of the nonwoven ground web. The resulting composites, which are products of the present invention, have similar strengths, durability, and improved workability as compared to similar nonwoven, low density, three dimensional abrasive products. The polymer layer can be a polymerized material that is polymerized from a liquid reactive component or that can be sufficiently fluidized by melt extrusion. They are coatable, curable compositions that cover the fibrous web. The term "curable" refers to any material that can cure from a polymer to a solid material at room temperature. Curing occurs in situ by coating the system on a nonwoven or woven material and then curing the reaction system (curing can be by UV, peroxide, or any other known curing method) ). Curing in the case of melt extrusion occurs as the polymer solidifies at room temperature. Generally, if the nonwoven, low density, three-dimensional web has a reinforced mesh or woven fabric, some of the fibers will penetrate the mesh or woven fabric. The polymer layer must be sufficiently thick to be in intimate contact with the fabric and to obscure fibers protruding through the fabric. The ends of the fibers are in the polymer layer and the opposite side of the nonwoven surface of the belt, pad, or disc is the "fiber-free" surface. "No fiber protrusion"
And the term "end is in the polymer layer",
Substantially the ends of the fibers extending from the web stop in the polymer layer, indicating that the web does not protrude from the surface of the polymer layer opposite to where the web is adhered.

For satisfactory performance, the hardness of the continuous polymer layer ranges from about Shore 50A to Shore 80D, preferably from about Shore 90A to Shore 70D. About Shore 90
For materials softer than A, excessive friction generates heat in some applications, which can thermally degrade this polymer layer. If the hardness of the polymer is greater than about Shore 70D, it is too hard for applications such as belts. However,
In some grinding disc applications, the composites of the present invention, which are somewhat less flexible, are preferred.

The thickness of the continuous polymer layer is typically
175 to 1750 μm, more preferably about 250 to 100 μm
The range is 0 μm. Polymer layers having a thickness significantly less than about 250 μm have poor integrity and durability. If the polymer layer is thicker than about 1000 μm, the resulting composite is too hard for some applications, which is undesirable. However, it will be appreciated that this depends on the choice of the polymer composition, and some layers are of the same thickness and are more flexible and flexible than others. The choice of polymer depends on the end use, as some applications require a rigid support. If a hard polymer is used, the composite will be excessively hard in many applications when using a thick polymer layer above about 1750 μm.

When the composite or nonwoven product of the present invention is used in the form of an endless belt, pad or disc,
It must have some flexibility to provide usefulness and adequate economic life. Further, in grinding or polishing belt applications, for example, where the working belt is supported by a stationary platen, the polymer layer must withstand heat generation in the environment of use. Conventional belts, where the fibers protrude from the opposite side of the grinding surface in contact with the platen, generally result in excessive heat generation.
When a workpiece is brought into contact with such a conventional belt, the protruding fibers are pressed against a platen and heat is generated by the operation of the belt. Friction heat is also undesirable from a safety standpoint and shortens the life of the belt or disk.

[0022] The continuous polymer layer may be formed from the polymerization of a liquid reactant. Useful reactive polymer systems include heat or radiation curable urethanes and epoxy resins. One such liquid reaction system is the two-part laminate adhesive composition described in Example 1 of U.S. Pat. No. 4,331,453. Preferably, the continuous polymer layer is a hot (melt) extruded polymer. Thermoplastic resins such as nylon, polyester, polypropylene, polyethylene / vinyl acetate copolymers, acrylic / butadiene / styrene copolymers, and thermoplastic elastomers such as ionomers, polyesters, polyurethanes, polyamide ethers, and the like are preferred melt-extruded polymers. The polymer layer may also contain compatible fillers, pigments, short reinforcing fibers, antioxidants, lubricants, and the like.

Preferred melt extrudable polymers have a melt flow temperature above about 115 ° C. as measured by Differential Scanning Calorimetry (DSC) as described in ASTM E 537-86. Melt extruded polymers with a melt flow temperature below about 115 ° C. in composite belts can fail prematurely in many applications when pressed strongly against a platen. This is because frictional heat is generated between the back surface of the belt and the platen. Melt extrudable polymers having a melt flow temperature above about 150 ° C. are preferred, especially for use in grinding belts where the workpiece is pressed strongly.

FIG. 5 shows a preferred method for producing the material of the present invention. Bulk nonwoven web 22 secured to woven fabric 24
Is subjected to a coating process together with the fibers 25 projecting through the woven fabric 24. (In the preferred method,
The nonwoven web 22 is previously needled into the woven fabric 24, a liquid bonding material is applied to the nonwoven web, and the bonding material is cured. This stack is fed under an extruder 26 having die holes capable of forming a sheet 28 of molten polymer. The polymer layer 30 is formed by placing the sheet 28 directly on the woven fabric 24 side of the laminate 20 and impregnating the protruding fibers 25. The two counter-rotating rolls 32 and 34 are arranged at regular intervals, and the surface of the polymer layer 30 is smoothed by pressing from both sides of the laminate. The rotating roller 34 is rotated so that the polymer layer 30 solidifies after contacting the roller 34.
Is cooled. The coated laminate obtained by the nip rolls 38 and 40 is led to a storage roll (not shown) or a cutting device (not shown) for cutting this coated laminate according to size and shape.

[0025]

EXAMPLES In the following examples, all parts are by weight unless otherwise specified. Although various embodiments of the bulky, porous, low density, abrasive materials of the present invention are illustrated, these examples are for purposes of illustration only and do not limit the invention.

[0026]

Comparative Example A In this comparative example, a polyester raw fiber material satin weighing 260 g / m ^2, a heat set,
Non-stretch woven fabric (available from Milliken, Inc.), needled by this, Land Webber machine
(Karatoru company from available) Weight 280 g / m per filament length 50mm from nylon 66 filaments having ² to a porous size and 25mm per 5.5 crimps are formed by using a
And a bulky, porous nonwoven aerated web of 60 denier. Place this nonwoven aerated web on a raw fiber material polyester cloth and add 15 × 18 × 25 × 3.5 RB 6-32-5.5
Using a B / 3B / 2E needle, about 20 needles per cm ^{2 of} the cloth surface were penetrated into the raw fiber material cloth and needled. The resulting composite had a thickness of about 75% above the center line of the woven fabric and about 25% below this center line.

The needled composite was roll coated with a polyurethane resin solution as shown in Table 1 below.

TABLE 1 Ingredient Parts by weight molecular weight of about 1500 ketoxime - blocked poly (1,4-oxybutylene) glycol-tolylene Lee isocyanate (trade name "Adiprene (Adiprene)" BL-16) 66.2 p, p'- methylene dianiline A mixed solution of 35 parts (sufficient to provide 1 NH ₂ groups for each NCO group) and 65 parts of ethylene glycol monoethyl ether acetate (trade name cellosolve acetate solvent) 22.9 Red pigment dispersion ( About 10% pigment, about 20% adiprene BL-16, and about 70% ethylene glycol monoethyl ether acetate solvent 10.9 Ethylene glycol monoethyl ether acetate solvent (addition of glycol monoethyl ether acetate increases the viscosity of the solution to 1,200 to 1,200). (Adjusted to 1,400 cps) Required amount

Next, a slurry of abrasive particles / phenol-formaldehyde resin having the composition shown in Table 2 below was spray-coated.

[Table 2] Ingredients by weight 2-ethoxyethanol solvent (trade name "Ethyl Cellosolve") 8.4 A-stage base catalyst phenol-formaldehyde molar ratio 1: 1.9 Phenol-formaldehyde resin (solid content 70%) 21.0 Viscosity about 700 cps , Acid value of about 3, and amine value of about 320 g (resin / amine equivalent) (available from Celanese Coatings under the trade name of "Epi-Cure 852") 4.8 Fused alumina abrasive particle grade 100-150 (Product name `` Alundum '') 59.4 Red dye (13% solids in ethyl cellosolve) 1.5 Petroleum (632-712 SSU second at 38 ° C, 70-75 SSU second at 99 ° C) 3.9 Bentonite 1.0

After heating in air at 160 ° C. for 10 to 15 minutes using an impingement oven, the resulting composite was weighed to be 1925 g / m ² and had a thickness of about 9 mm.

[0030]

EXAMPLE 1 The back side of the nonwoven composite described above as Control Example A (25% of the fibers protruding from this back side) was melted with nylon 6,10 (commercially available from EI Dupont). Layers (melt flow temperature 220 ° C.). It flowed over the fibers protruding from the back of the needled raw fiber material polyester fabric web laminate. The molten coating was applied from an extrusion die slot of the same width as the nonwoven composite. The nonwoven composite was immediately passed through two counter-rotating steel rolls rotating at the same surface speed as the nonwoven composite, and the ground surface was partially contacted at room temperature with a first roll having a diameter of 150 mm. A second 760 mm diameter steel roll was cooled to about 15 ° C. with water. Extruded nylon 6,10 by a single screw extruder equipped with a slot die heated to 230 ° C.
A molten film was formed. This slot die is 350 ~ 450
It has a gap of μm. This molten film, hanging about 100 mm from the slot die, contacted the back of the nonwoven composite just before the nip between the two steel rolls. As the nonwoven composite and molten nylon polymer passed between the rolls, the molten polymer was pressed against the fibers on the back of the nonwoven composite, and the polymer surface was flattened by a second chill roll. The rate at which the molten nylon flows out of the slot die to form the material of the present invention is necessarily the same as the rate of movement of the nonwoven composite;
It was about 0.15 m / s. The weight of the coated nylon 6,10 was about 265 g / m ² and the thickness was about 300 μm. The feel of this coating was very smooth. The resulting complex weighs
It was 2100 g / m ² , about 10 mm thick, and had appropriate hardness.

The composite for nonwoven grinding of this example was cut into a width of 50 mm, and an endless belt having a length of 865 mm was prepared for a conventional coated grinding belt sander. To form a butt splice, a strip 50 mm wide was cut at an angle of approximately 30 ° from perpendicular to the long side of the belt. The fibers protruding through the melt-coated nylon polymer as well as the raw fiber fabric were then removed by abrading the ends on the backside. Then, a belt butt joint was performed using a conventional polyurethane joint adhesive and a heating joint press. The 50 × 865 mm nonwoven grinding composite belt of Example 1 was evaluated in comparison with Control Example A. This belt is portable, with a 150 mm long platen that supports the belt when the belt is pressed against the workpiece.
It was mounted on an air-driven, hand-held, platen sander (Model Dynangle II 14050, manufactured by Dynabrade Co.). Speed 20.2
Operating at 3 m / s, the belt is pressed for 3 minutes with a control force of about 67 Newtons against a 15 mm thick steel plate edge with a 6 mm radius edge.

In the belt of Example 1, deterioration of the back surface of the belt was not observed, the platen was slightly heated, and the belt contacted the platen and rotated smoothly.

In Control Example A, which employs a similar procedure, high heat is generated at the platen, causing significant degradation of the fibrous protrusions, resulting in grabbing and jerking of the platen, resulting in a smooth surface. During rotation for a long time without rotation, abrasion of the platen surface was observed.

[0034]

Example 2 The nonwoven laminate of Control Example A was coated as shown below. Hytrail (Hytr
el) ", a thermoplastic elastomer (available from EI Dupont) having a Shore 40D durometer hardness and a melt flow temperature of 158 [deg.] C, commercially available under the trade name of 4056. The melt extruded slot die was maintained at 250 ° C. The paint was dropped from about 50 mm above the laminate on the back side of the laminate of Comparative Example A at a point about 25 mm ahead of the nip formed by two steel rolls of 100 mm diameter. The coated web was then passed between rotating nip rolls at a speed of 0.025 m / s and led into a water cooling bath (10 ° C.) where the lower half of the rolls were covered. The nip roll was pressed against the fibers protruding through the raw fiber material and positioned to provide a smooth surface. The composite was partially wrapped around a roll and brought into contact with the melt-extruded coating and then introduced into a water-cooled bath. The weight of the molten polymer was 1075 g / m ² and the thickness was about 950 μm. The nonwoven composite of this example is very flexible. The composite nonwoven grinding material of this example was prepared on a 50 × 865 mm belt, and evaluated by a hand-held platen sander according to the procedure shown in Example 1. Heat generation was low, smooth rotation was obtained, and there was no deterioration of the back surface of the belt.

[0035]

Example 3 Instead of "Height Trail" 4506 polymer, E.
I. The same procedure was followed as in Example 2 except that a Shore 82D durometer thermoplastic polyester elastomer having a melt flow temperature of 223 ° C., commercially available under the trade name “Heightrail” 8256, available from DuPont, was used. The composite for nonwoven grinding of the example was prepared. The extrusion die was kept at 300 ° C. The melt-coated paint was applied at a weight of about 625 g / m ² and applied to a thickness of about 1000 μm. The resulting structure was harder than Example 2. The product had satisfactory performance in the handheld platen tester described in Example 1 showing slight heat generation and good flexibility.

[0036]

Example 4 B. Instead of "Height Trail" 4056 Polymer
Example 2 except using a Shore 48D durometer thermoplastic polyester elastomer having a melt flow temperature of 115 ° C. available from F. Goodrich Company under the trade name “Estane” 58409
In the same manner as in the above, a composite for nonwoven grinding of this example was prepared.
The extrusion die was kept at 210 ° C. and layer coated to a thickness of 1000 μm, 1125 g / m ² . The resulting nonwoven composite was moderately flexible and the belt formed therefrom was evaluated by the platen sander test described in Example 1. Some heat generation was observed and slight evidence of degradation was seen on the back of the belt. However, the performance of the overall belt is satisfactory and is improved over conventional belts.

[0037]

Example 5 Exxon Chemical Company under the trade name of "Escorene" 3014 instead of "Height Trail" 4056 polymer
A nonwoven grinding composite of this example was prepared in the same manner as in Example 2, except that polypropylene having a melt flow temperature of 170 ° C. available from (Exxon Chemical Company) was used. The extrusion die is kept at 210 ° C and the final coating weight is 940g /
A layer having a thickness of m ² and a thickness of 1000 μm was obtained. The obtained nonwoven composite had an appropriate hardness, and was suitably used for applications requiring a hard belt.

[0038]

Example 6 Instead of the "Height Trail" 4056 polymer, the trade name "Grade" B860 is used by Chevro.
The nonwoven grinding composite of this example was prepared in the same manner as in Example 2 except that polyethylene having a melt flow temperature of 114 ° C. available from n Corporation) was used. The extrusion die was kept at 150 ° C. to obtain a layer having a coating weight of 1075 g / m ² and a thickness of 1000 μm. The resulting nonwoven composite was more flexible than the composite of Example 5. The belt formed from this composite showed degraded flow of the polyethylene layer when evaluated on a handheld platen sander. However, it can be used for applications that do not require a severe load on the platen.

[0039]

Example 7 U.S. Pat.
The nonwoven low density grinding product described in 331,453 was prepared without the lamination step. The nonwoven grinding support was a fibrous nonwoven structure having no woven fabric as reinforcement, and the material weighed about 775 g / m ² and had a thickness of about 9 mm. The resulting composite structure was about 10 mm thick, weighed about 880 g / m ² , and the melt-coated layer was about 380 μm thick. A disk is cut from the composite and assigned to the assignee's U.S. Pat. No. 3,562,96.
The drive button was adhered to the molten polymer support as described in No. 8. The nonwoven composite is used as a useful surface treatment tool using the holder described in U.S. Pat.No. 3,562,968, with the polymer layer protecting the holder in the event that the nonwoven layer becomes thin due to wear. Functioned as a layer.

[0040]

Example 8 Instead of "Height Trail" 4056 polymer,
10 containing 35% diisononyl phthalate plasticizer, about 59% medium molecular weight polyvinyl chloride, and about 6% stabilizer
As in Example 2, except that a plasticized polyvinyl chloride thermoplastic mixture having a melt flow temperature of 1 ° C. was used,
A composite for nonwoven grinding of this example was prepared. Extrusion die 19
While maintaining the temperature at 0 ° C., a coating having a coating weight of about 1350 g / m ² and a thickness of 1000 μm was coated on the back surface of the cloth. When the obtained nonwoven composite was evaluated in the same manner as in Example 1, the same performance as in Example 1 was not obtained due to the deterioration flow of the polymer layer. However, the platen was not heated as in the control example. Belts made from this composite can be used in applications where severe loading on the platen is not required.

The specific details set forth herein above are by way of example only and should not be construed as limiting the invention. Various modifications and changes which do not depart from the spirit of the present invention of the detailed examples are included in the scope of the present invention described in the claims.

[Brief description of the drawings]

FIG. 1 is a perspective view of a grinding belt of the present invention.

FIG. 2 is a perspective view of a grinding disk of the present invention.

FIG. 3 is a partially enlarged side view of the grinding belt of the present invention having a reinforcing woven fabric.

FIG. 4 is a partially enlarged side view of the grinding belt of the present invention without a reinforcing woven fabric.

FIG. 5 is a schematic diagram illustrating a method of manufacturing one embodiment of the material of the present invention.

FIG. 6 is a partially enlarged side view of a conventional grinding belt.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 ... Grinding belt 11 ... Three-dimensional fiber layer 12 ... Stretch-resistant reinforced woven fabric 14 ... Polymer layer

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI B32B 27/04 B32B 27/04 Z 27/12 27/12 (72) Inventor Gary Michael Farris St. Minnesota 55144-1000 United States・ Paul, 3M Center (No address is indicated) (56) References: JP-B-49-24804 (JP, B1) (58) Fields investigated (Int. Cl. ⁷ , DB name) B24D 3/00-18 / 00 B32B 5/02-5/08 B32B 27/04 B32B 27/12

Claims (5)

(57) [Claims] 1. A non-woven three-dimensional layer having a porous bulky web, wherein the synthetic fibers are crimped and bonded with a bonding material at points of substantial mutual contact; and (b) the non-woven layer. A reinforcing polymer layer fused to one major surface of the non-woven layer and having the ends of the fibers from the nonwoven layer introduced therein; and (c) provided between the polymer layer and the nonwoven layer A material for surface treatment, wherein fibers derived from the nonwoven layer are introduced into the polymer layer through the reinforcing woven fabric. 2. The material of claim 1, wherein said bonding material comprises abrasive particles. 3. The thickness of the polymer layer is about 175-17.
The material according to claim 1, which is 50 µm. 4. The material of claim 1, wherein said polymer layer comprises a polymer having a melt flow temperature greater than about 115 ° C. 5. The polymer layer comprises a cured polymer having a hardness of about Shore 90A to about Shore 70D.
The material of claim 1.